Tacking Axle caps

[Antman]

I just rebuilt a couple sets of Dana 30 axles, (upgraded to 5-760X Joints), and noticed a couple of things. 1st, one set of axles have about 190,000 plus miles on them. 2nd, I had tacked the caps about 25,000 miles ago. I ground the tacks off and with the help of PB Blast got the old joints out. The original set of joints in the high mile axles had as much grease in them as my "bought last year" OEM's did. I now have 2 sets of spare D30's with 5-760X joints in them. After seeing there was no ill effects on the previous axles, I tacked the new joints. :D

I also masked off and painted half the ear and joint black and the other half white so I can see if they spin. :) From my experience, the half circle clips get spit out when the caps spin, which is due to the ears stretching, so tacking the caps probable gives you a little longer before the ear stretches to the point of failure. Rust on your caps is a friend!:D

BTW I have an extra pair of TJ D30 axles with upgraded joints for sale. :D

[RufftyTuffty]

Another option is recess the yokes with a grinder and get some full circle clips from NAPA.

[Antman]

Another option is recess the yokes with a grinder and get some full circle clips from NAPA.

The Napa up here in Show Low doesnt have a clue about full circle clips!:(

[xFallen]

The Napa up here in Show Low doesnt have a clue about full circle clips!:(

They could order them for you, or you can order them from the 'net from several places (Randy's R&P is one).

It really sounds like you have had good luck tacking the caps so for me I'd stick with what I know works (and 25K from a set of 297 u-joints on a wheeled rig isn't bad at all!), but I have seen some ill effects from the tacking approach too. The full circle clips have been great for me with the added benefit of being able to change a u-joint should the need arise.

I like the idea of painting the caps. I leave mine dirty so I can see if they have moved but the two-tone paint job is probably even better. I used black permanent marker once but that lasted about a month maybe two.


Barry

[Renob]

The full circle clip is just a snap ring and can be had at most any hardware or auto parts store. Take one of your caps with you to get the correct size. And if you don't already have them, pick up a set of snap ring pliers while you are there.

[Antman]

The full circle clip is just a snap ring and can be had at most any hardware or auto parts store. Take one of your caps with you to get the correct size. And if you don't already have them, pick up a set of snap ring pliers while you are there.

Your absolutely right! My local ACE Hardware has them! :D I took a full circle along with me and matched it up!:D

I usually carry spare axles with me along with spare joints, and also carry a grinder, (I also have a 800 watt inverter), to grind the tack welds off if I need too.

Also the set of 297's went over 170,000 BEFORE I tacked them!!! :eek: Then another 20,000 or so before upgrading them. They actually were getting sloppy, but still had grease and all the bearings in them. That set of axles have been to the Cracks 20 times or more and Pyaette Draw 6 or 7 times and to Moab for the last 4 years.

I am now, thanks to Nick, running Cro Mo's with full circle clips, and have 2 sets of spare OEM's with 5-760X U joints.